Date: 18 Jul 2006 CIRCULATE: TO Service Mgr Warranty Workshop Body Shop Parts X X X X X CHANGES MADE FOR ISSUE "3" ARE HIGHLIGHTED WITH GREY BACKGROUND SECTION: 204-05 Electronic Air Suspension Fault Codes AFFECTED VEHICLE RANGE: Land Rover LR3 (LA) VIN: 5A000360 to 6A374641 CONDITION SUMMARY: ELECTRONIC AIR SUSPENSION (EAS) WARNING MESSAGE AND LAMP ILLUMINATION Situation: A customer may report a warning message "Suspension Fault Normal Height Only" from the message center accompanied by the Air Suspension Warning Lamp illumination. Diagnosis using the Integrated Diagnostic System (IDS) reveals Diagnostic Trouble Code (DTC) C1A20-64 (pressure increases too slowly while filling reservoir) or C113192 (unable to pressurize gallery). No air leaks are found. The compressor exhaust valve is sticking, causing an internal air leak when the compressor is active. Action: Should a customer express concern regarding the above, refer to the Repair Procedure detailed in this bulletin to repair the air compressor using a delivery valve/exhaust valve repair kit and update the air suspension Ride Level Control Module software. Compressor replacement will only be required in rare circumstances as specified in the Repair Procedure. PARTS: JPO500010...Compressor repair kit Qty 1 NOTE: Part RQG500090 is the latest specification air compressor with a stronger exhaust valve return spring. When the new air compressor is installed the air suspension Ride Level Control Module software must be updated to the latest specification using WDS CD13 or IDS DVD102 or later. NOTE: The air compressor assembly, RQG500090, can be identified by a yellow label on the end of the assembly. The yellow identification label will be replaced by case stamped identification. RQG500090...Air compressor assembly Qty 1 TOOLS: WDS Diagnostic Disc...CD13 or later IDS Diagnostic Disc...DVD102 or later 303-D121...Puller (modified to two leg condition) 303-588...Protective button from this tool NOTE: The information in Technical Information bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment required to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by do-it-yourselfers. If you are not a Retailer, do not assume that a condition described affects your vehicle. Contact an authorized Land Rover service facility to determine whether the bulletin applies to a specific vehicle. Land Rover 2006 Page 1
WARRANTY: NOTE: Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time. DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero. Description Check delivery valve. Renew delivery valve and install exhaust valve kit. Reconfigure air suspension control module Check delivery valve where necessary. Replace compressor. Reconfigure air suspension control module. Replace compressor. Reconfigure air suspension control module. SRO Time (Hours) Condition Code Causal Part 60.50.89/44 1.0 42 RQG500072 60.50.89/43 0.8 42 RQG500072 60.50.89/43 0.8 42 RQG500072 Normal warranty policy and procedures apply. Land Rover 2006 Page 2 of 7
REPAIR PROCEDURE AIR LEAK INSPECTION 1. Verify no air leaks are found at any of the following locations: Compressor Reservoir solenoid valve block Reservoir Front solenoid valve block Rear solenoid valve block Intermediate connections and pipe work ALL COMPRESSOR REPAIR PROCEDURES IN ISSUE "3" ARE NEW INFORMATION AIR COMPRESSOR INSPECTION NOTE: The part number can be a stamped number, a self-adhesive label carrying the new part number or it may be written with a paint-pen. 1. Locate the air suspension compressor mounted on the left side frame rail and inspect the crank case end plate for the part number. (Figure 1) 2. Refer to the table below and determine the action required from the observed compressor part number. Figure 1 Part Number RQG500080 RQG500090 RQG000017 RQG000018 RQG000019 RQG500060 RQG500061 RQG500070 RQG500071 RQG500062 RQG500072 Action Required Latest level compressor. No further compressor action should be required. Diagnose the root cause of the problem. Check delivery valve. If delivery valve is damaged, replace the air suspension compressor. If delivery valve is not damaged, install a new delivery valve and install the exhaust valve kit. Install a new delivery valve and install the exhaust valve kit. NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LA LR3/2005 > Workshop Manuals > Bookmark "Suspension/ 204-05: " Link "Air Suspension Compressor (60.50.10)" 3. If the compressor part number is anything other than RQG500080 or RQG500090, remove the air suspension compressor from the vehicle. Land Rover 2006 Page 3 of 7
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LA-LR3/2005 > Workshop Manuals > LR3 Workshop Manual > Bookmark "Chassis / Suspension / 204-05 Vehicle Dynamic Suspension > Link "Air Suspension Compressor (60.50.10)" Figure 2 CAUTION: Plugs installed in the open connection locations are required to prevent contamination. 4. Install plugs to the open connections of the inlet and outlet pipes of the compressor being inspected and clean the compressor assembly. (Figure 2) 5. Undo and remove the delivery valve-retaining plug: (Figure 3) Remove and discard the retaining plug O-ring seal. Remove the return spring and the delivery valve and discard the spring. Inspect the delivery valve for damage ( Figure 4) Figure 3 6. If the compressor has part number RQG000017, RQG000018, RQG000019, RQG500060, RQG500061, RQG500070 or RQG500071 select the proper repair as follows: If the delivery valve is damaged (left image in Figure 4) replace the air compressor with a new unit following GTR section 60.50.10 procedures. If the delivery valve is not damaged, (right image in Figure 4) perform the Compressor Repair Procedure that follows. 7. If the compressor part number is RQG500062 or RQG500072 or if the delivery valve is not damaged in the above inspection, perform the Compressor Repair Procedure that follows. Figure 4 DAMAGED UNDAMAGED Land Rover 2006 Page 4 of 7
COMPRESSOR REPAIR PROCEDURE NOTE: This repair procedure only applies to a compressor that meets the following criteria: Part number RQG000017, RQG000018, RQG000019, RQG500060 RQG500061 RQG500070 or RQG500071 that upon inspection have an undamaged delivery valve. Part number RQG500062 or RQG500072. Figure 5 1. Install new delivery valve assembly from kit JPO500010 as follows: (Figure 5) Install a new O-ring seal to the delivery valve-retaining plug. Assemble the new spring and new delivery valve. Install new spring and new delivery valve into the compressor. Tighten the delivery valve-retaining plug to 12.5Nm (9.2 lbf.ft). 2. Undo, remove and discard two diagonally opposed exhaust valve plunger cover securing screws to permit puller installation. (Figure 6) 3. Configure special tool 303-D121 to two-leg mode or alternatively, use a suitable two-leg puller. (Figure 7) 4. Install and align special tool 303-D121 and the protective Figure 6 button from tool 303-588 to the exhaust valve plunger cover. (Figure 8) 5. Hand tighten the tool only enough to hold the plate in position. 6. Undo, remove and discard the two remaining plunger cover securing screws. (Figure 8) 7. Clean area around each screw hole using a vacuum cleaner to prevent debris from entering the plunger chamber. 8. Carefully back off the puller, allowing even reduction in the cover spring pressure. Figure 7 Figure 8 From 303-588 Land Rover 2006 Page 5 of 7
9. Remove the tool and the cover when spring tension is relaxed. 10. Remove and discard the orange O-ring seal. (Arrowed in Figure 9) 11. Install the new inner spring and spacer from kit JPO500010 at the center of the original outer spring. (Figure 9) 12. Install and fully seat the new orange O-ring seal from kit JPO500010. 13. Install and align the plunger cover. Figure 9 CAUTION: The cover must be positioned and clamped evenly during the following step. 14. Install the puller and the "button" special tool and carefully tighten the puller to compress the springs to a snug seated condition. (Figure 10) CAUTION: Care must be exercised to avoid crossthreading the new screws being installed. Proper installation is best performed by positioning the screw in the hole, rotating the screw counter-clockwise until a 'click' is heard and then rotating the screw clockwise by hand a minimum of two turns to engage the threads. 15. Install and finger tighten the two exposed cover screws to secure the cover. (Figure 10) 16. Undo and remove special tool 303-D121. 17. Install and finger tighten the two remaining new plunger cover screws. (Figure 11) 18. Tighten the final two screws to 5Nm (3.6 lbf.ft). 19. Tighten the first two screws installed to 5Nm (3.6 lbf.ft). 20. Using a suitable paint marker, strike through the original part number on the compressor to identify that the unit has been repaired. 21. Refer to GTR section 60.50.10 and install the repaired compressor unit to the vehicle. Figure 10 Figure 11 From 303-588 Land Rover 2006 Page 6 of 7
INSTALL LATEST EAS SOFTWARE CAUTION: A Midtronics PSC-550 Vehicle Power Supply must be connected to the vehicle battery during diagnosis and module configuration. 1. Connect the diagnostic equipment to the vehicle and begin a WDS/IDS session. 2. Determine the current software levels of the Ride Level Control Module as follows: Enter the vehicle details. When prompted "Do you wish to read trouble codes?" select "NO" and press the tick-box to continue. Select the 'Vehicle Configuration' tab. Select 'Module Information'. Select 'Network Integrity Test'. Note the software part numbers displayed on the screen. NOTE: Following EAS software download, the suspension ride height will not require re-calibration. 3. Configure the Ride Level Control Module software as follows: Return to the 'Vehicle Configuration' screen and select 'Module Configuration.' Check the software part number displayed on WDS/IDS screen is different than the software part number noted in Step 2 'Module Information' above. Select 'Configure Existing Modules.' Select 'Ride Level Control Module' from the sub-menu. Check the tick-box to continue and follow the on-screen instructions. 4. Repeat step 2 to confirm the software level change. 5. Exit the WDS/IDS session and disconnect the diagnostic equipment from the vehicle. Land Rover 2006 Page 7 of 7